Method of forming charges



Feb. 4, 1936.

LH. DERBY ET AL METHOD OF FORMNG CHARGES Filed oct. 6, 1932 Sheets-Sheet 1 Feb. 4, 1936. l. H. DERBY Er AL l 2,029,761

METHOD lOF FORMING CHARGES Filed oct. e, 1952 s sheet-'sheet 2 Feb. 4, 1936. H. DERBY Er Al.

l METHOD oF 'FORMI NG CHARGES A3 Sheets-Sheet 3 Filed Oct (Ittornegs.

w. vr ne 32 M a r j Patented Feb. 4, 1936 j UNITED STATES PATENT OFFICE METHOD F FOBMING CHARGES E Ira Il. Derby and Harold B. Horner, Indianapolis, Ind., assignors to Peter C. Reilly, Indianapolis,

v Application October 6, 1932, Serial N0. 636,611

Claims.

This invention relates to an improved method' siderabie carbon residue, and certain gases;and this under `maximum thermal emciency and mini- `mum operating costs.

By carbonaceous materials we refer to such substances as coal. lignite, wood, oil shale, coal tar pitch, pitch,- and any other material that when heated yields certain of the substances orl bodies just above mentioned.

y By condensates we means all the condensible volatile matter resulting from the distillation of thefabove named materials.

By gas we mean such substances as do not liquefy under normal conditions.

,A The invention relates more particularly to a preferred method of forming charges of material, auch charges having preformed channels therein through which the gaseous treating medium is drawn. y y 1 l j,

In our application'fserial $18,812. filed Januaryv 4, 1930, we have broadly the method of treating solid `carboxiiable'f'material to distill and'carbonize lthe samewherein a charge of the material was formedwith a plurality of spaced channels extending therethrough, subjecting the exposed surface of the `charge to "the action of a fluid heating medium and drawing Fig. 3,^an enlarged detail view such medium, together with the distillates evolved in the treatment of the charge, through the channels in the charge and in direct contact with the material from lwhich the charge is formed. The present invention has to do with the means whereby such charges may be formed in-receptacles to be placed in a retort or in forming the 'charge in the retort proper. 1

The charges thus formed'may be introduced v into 'a retort for treatment, such for instance las is shown in our copending application, Serial No. 685,779, filed August 18, 1933. as a division or our application serial No. 636,612, med october 6, 1932, or as of even date herewith.

In the drawings: Fig. l is a vertical sectional view of a retort with the channel-forming tubes placed therein. said tubes being illustratedas filled with inert material; v l s r1ig.2.asimilarviewwherein thespaoesbetween the channel-forming tubes have been partially filled with coal or other carbonaceous material to be treated;

tomamtion of the tubes and the plate employed for closing the space intermediate the tubes while the tubes are being filled with inert material;

Fight, a like view showing the cap or die plate which closes the upper ends of the tubes when the material is being fed inwardly between the tubes;

` Fig. v5, a detail sectional view of the lower portion of the tubes and the perforate supporting diaphragm underlying said tubes;

Fig. 6, an enlarged detail view of one side of the retort showing the upper portion of the completed charge;

Fig. 7, a horizontal sectional view taken on the line VII-VII of Fig. 1;

' Fig. 8. a like view taken on the line VIII- VIII of Fig. 2 with portions of the supporting frame for the tube covering caps removed or broken Sway;

Fig. 9, a fragmentary detail view of the supporting diaphragm above referred to;

Fig. 10, aperspective view of one of the chargereceiving receptacles;

Fig. 11, alike view of one of the perforatefreceptacle bottoms;

Fig. 12, a detail fragmentary perspective view of means employed to introduce channeling material into the pan or receptacle preparatory to filling the body of the pan with the material ,the channeling or spacing material being shown in their final position.

As above indicated, the method of forming the charge to be treated may be employed directly in a retort or may be employed to form the charge within a receptacle, which receptacle is thereafter introduced into a retort for. treatment of the-charge.

` Referring first to Figs. 1 to 9, both inclusive, wherein the charge is formed within a retort and a batch method employed, i denotes the retort having a removable bottom 2 above which, and standing in a spaced relation thereto, is a perforate diaphragm or support I having a grid-like form, as shown in Fig. 9, or other suitable form which will allow a gaseous medium and products produced in the treatment of the charge to pass downwardly therethrough. a

The member 3 is mounted for sliding movement in and out of the retort and will preferably be actuated through the medium of a hydraulic \cylinder 4. An off-take 5 opens into the chamber inthe lower portion of the retort above the bottom 2, said off-take being connected with a suitable exhauster (not shown).

The upper portion of the retort is provided `with a closure 6 and al plurality of burners I spaced away from the cover 6 lie above the normal level of the charge. Any suitable fuel may be employed in conjunction with said burners.

To place a charge within the retort having preformed channels extending therethrough and through which the gaseous or uid heating medium will be drawn, the following means may vbe utilized. A series of tubes 8 are interconnected and held in vertical position and in horizontally spaced relation by cross rods or bars 9 which in turn are connected to a frame-Work I0, shown in the instant case as rectangular to t within the retort. The tubes are of such length that when the frame Ill comes to rest upon a shoulder or projection II extending inwardly from the Wall of the retort the ends of the tubes stop short of the charge-supporting grid or element 3. This relationshipof the tubes to the grid is best shown in Fig. 1 wherein the tubes are shown as lled with solid granular material infusible at the temperature employed, such as coke formed from a previous run upon a charge of coal (when coal is being treated). At such time, or when the tubes are being filled, the spacers between the tubes are closed off by a plate I2 having openings I3 therein which register with the openings in the upper ends of the tubes. This plate rests upon the upper ends of the tubes and is of such dimension as to extend from Wall to wall of the retort.

Where the tubes stop short of the removable bottom 23 of the charge-receiving receptacle, or retort as the case may be, the channel filling or forming material will spread out laterally to a certain degree, and thus insure that there will always be a -passage downwardly through the grate-like member 3 or the openings in the false bottom 23, as the case may be. Otherwise, the coal or other material to be treated might close olf the'openings and prevent downilow ofv the .heating medium through all the channels alike. Where the false bottom is formed from a series of laterally spaced bars, as in our copending application Ser. No. 685,779, and supporting bars are introduced therebetween to support the charge while the false bottom is lowered, the outspreading of the channel forming material is essential as the bottoni surface of the charge may,.of course, be disrupted to a slight degree.

When the tubes are lled, as shown in Figs. l and 3, the plate I2 is removed and the upper ends of the tubes are then closed by cap pieces or dies I4 which are interconnected with each other by rods I5. Said rods are connected at their outer ends or extremities to a frame I 6, which when positioned as shown in Figs.` 2 and 4 brings the cap pieces in alignment and directly over the upper ends of the tubes 8, the frame coming to rest upon the underlying tube-supporting structure.

The space between the tubes 8 is then filled with the material to be treated, say for instance coal, the upper level of the coal being brought approximately to the level of the underside o1 the ledge II. When this is accomplished the cap-carrying frame is lifted out of the retort and the tube-carrying frame 1s gently elevated stripping the tubes from the charge and allowing5 the relatively fine granular material within the tubes to spread and fill up the spaces occupied by the Withdrawn tubes. This results in the upper surface of the charge being substantially level over its entire surface, as best shown in' Fig. 6.

The cover ofthe retort is then closed and secured and the burners 1, which have been lighted, supply the necessary heat to the charge to convert it. The gas passing downwardly through the pre-formed channels is evenly distributed throughout the entire mass. It will of course be appreciated that molten metal or other fluid heating medium may be employed in place of gas.

When the process is rst started the greatest heat of course obtains in the upper portion of the charge where the material is converted into coke, if coal is the material undergoing treatment. The heating gases, and those evolved in the treatment of the material, are drawn downwardly through the permeable channels and the material is rst gradually heated and then converted into coke. l

By the utilization of the substantially evenly spaced permeable channels a large surface area is exposed to'the. action of the gaseous or other heating medium and furthermore no irregular channeling of the material by the gaseous medium obtains as frequently happens when a charge is placed in a retort and the gaseous medium drawn or lforced. therethrough. Moreover, by subdividing the charge with the channels the heating medium has an opportunity to impart its heat not onlyto the surface Vbut allows a. quick penetration of the heat to the entire charge. Thus conversion takes place rapidly and evenly.

In Figs. 10 to 15 there is illustrated means for forming a pre-channeled charge within a receptacle which may be introduced into a retort. Such a receptacle is particularly applicable for use in an apparatus as set forth and described in our copending application Serial Number 636,- 610, led October 6, 1932, and more particularly in conjunction with the apparatus shown in our` copending application Serial No, 685,779, led August 18, 1933, wherein the receptacles with the pre-formed charges therein are introduced successively into the retort and are discharged therefrom in an empty condition, the converted material having been removed from the retort.

The receptacle may be of any desired form and in Fig. 10 a rectangular receptacle 20 is shown, said receptacle having vertically disposed guideways 2| and 22 at one end thereof. The receptacle may be strengthened in any desired manner and the removable bottom 23 is designed to t closely therein and is sustained upon members 24 and 25 secured to the inner face of the lower portion of the receptacle.

'I'he perforate bottom 23 is shown as provided with a. pair of lugs or fingers 26 and 2'I whichy thereon, as best shown in Fig. 14, with the lower Y concerned any form of receptacle may be employed so long as it has a perforate bottom.

With a view of forming pre-formed channels of material, infusible at operating temperatures, within the receptacle. horizontally spaced tubes, as 28, interconnected to each other and to a frame 29 by cross bars 30 are employed. Said frame will preferably be formed of angle iron and of such dimensions that when placed upon the upper edge of the receptacle 20 it will rest ends of the tubes lslightly elevated from the bottom 23. The tubes 28 are then lled with granular material, such as coke produced as the resuit of the previous run.

It will be appreciated, of course, that inasmuch as the material which is introduced into the tubes 2l is granular and infusible at the operating temperatures employed, they remain open, or in other words, free to the passage ofthe products of combustion and gases which are introduced into the retort or evolved from the `material undergoing treatment; this at all times.

After the tubes are filled their upper ends are covered by. a series of caps 2| connected to a series of cross bars 32, which latter in turn are connected toa rectangular frame 23. The receptacle is then illld with the material to be treated, as for instance coal, the level whereof is somewhat below the upper edge of the receptacle and belowtheupperendsofthelledtubes (seeFig. 14). When this is effected the frame carrying thecappiecesisremovedandthenthetubesare graduallywithdrawn by elevation of the frame 2l.-

Asthetubesarewithdrawnfromthereceptscle the granular material therein will spread laterally and thus i111 the spaces voided by the mbes. This results in the production of a substantially level upper surface upon the charge witli the upper ends of the pre-formed channels fully exposed. The position of the charge within the receptacle is then as shown in Fig. 15 with a series of channels nlled with infusible material extendingy from the upper to the lower faces of the charge and evenly spaced throughout th mass of the charge.

It is. of course, manifest that instead of employing tubes which are withdrawn from the charge, tubes of combustible material, such for instance as card-board, may be utilized in forming the channels. In otherwords, the tubes-will be positioned .within a retort or receptacle in spaced relation. the tubes being filled with spacer material and the space about and around them thereafterl filled with the material tn be treated. In the claims where the term "receptacle" is employed it is to be understood as referring to a retortasshowninFigaland2ortoapanor receptacle as shown in Fig. 10, unless the wording ofthe claimrendersitspecifictoaretort orto a receptacle as such.

While we have described first the illling of the tubes and then surrounding them with the materlal to be treated. .it will be apparent that the tubes may be filled last and then withdrawn from the charge. Under such operation the tubes would be made of such a length-as to rest upon the perforate support so as to-insure the extension of the inert material entirely through the mass.

It will, of course, be appreciated that the tubes may be of any desired cross sectional area and ,of

any conformation or outline in cross section. It

will also be understood that the channels. while shown as vertically disposed, may be placed horizontally by orienting the receptacle in which the charge is formed, and that the fluid heating medium may be withdrawn from either end of the same under either dispo'sitionof the channels.

- What is claimed is:

1. That method of forming a charge of solid carbonizable material with a view of subjecting the same to the action of a fluid heating medium to distil and carbonize4 the same, which comprises placing a series of horizontally spaced, vertically disposed open-ended tubes within a receptacle, said tubes terminating close to but short of the lower end thereof; filling the tubes with a permeable material infusible under the action of the heating medium which is at a temperature to' distil or carbonize the charge; lling the receptacle about said tubes with the material to be treated; and, finally, withdrawing the tubes. thereby forming a pluralityof spaced channels defined by the permeable material opening at opposite faces of the charge, with the last named material ouispread at the lower ends of the channels.

2. That method of forming a charge of solid carbonizable material with a view of subjecting.

the same to the action of a fluid heating medium to distilor carbonize the charge, which comprises placingial series of laterally spaced, openended, vertically disposed tubes within a receptacle; filling said tubes with a granular material infusible under the action of the fluid heating medium which is to be employed; filling the remaining space in the receptacle with the material to be treated; and nally withdrawing the tubes. leaving the infusible material within the charge and extending therethrough from opposite faces thereof. 4

3. That method as set fo'rth in claim 2, wherein the lower ends o'f the tubes lwhich are placed in the receptacle stop short of the bottom thereof, whereby the infusible material spreads laterally with reference to such ends prior to the placement of the material to be treated.

4. That method as set fo'rth in claim 2, wherein the lower ends of the tubes which are placed in the receptacle stop short of the bottom thereof, whereby the infusible material spreads laterally with reference to such ends prior tothe placement of the material tobe treated, the upper ends of the tubes being covered during the filling -of the receptacle with the material to be treated.

5. That method of forming a charge of solid carbonizable material with a view of subjecting the same to the action of a fluid heating medium to distil and carbonize the same, which comprises placing a series of horizontally spaced. vertically disposed, open-ended combustible' tubes within a receptacle, said tubes terminating Just short of the bottom of the receptacle; filling the ltub withl a permeable material infusible under the action of the heating medium which is at a temperature to distil or carbonire the charge; filling the receptacle about said tubes with the material to be treated, thereby forming a plurality vof spaced channels dened by the infusible permeable material opening at opposite faces of thecharge, with the la'st named mate- 70 rial outspread at the lower ends of the channels.

ma H. DERBY. minou) B"s HORNER.

- CERTIFICATE OF CORRECTION'.

Fatent No. 2,029, '761 February 4, 1936.

IRA H. DERBY, ET AL.

It is hereby certified that error appears in the printed specification of the above numbered patent requiring correction as follows: Page 3, second Column, line 22, claim 1 before "permeable" insert infusible; and that the said Letters Patent should be read with this correction therein that the same may conform to the record of the case in the Patent Office.

Signed and sealed this 3rd day of March, A. D. 1936.

Leslie Frazer (Seal) Acting Commissioner of Patents 

